Methods and systems for recycling end-of-life photovoltaic modules

ABSTRACT

Methods of rapidly debonding encapsulant in solar modules and disassembling the modules for reuse or recycling of components. Electromagnetic radiation is applied to a solar module in a temperature and humidity-controlled environment to debond the encapsulant layers. Peel blocks are used to separate the front layer and back sheet of the module from the solar cells. The components are then sorted for reuse or recycling of valuable materials. The embodiments described also include a system of performing the methods that can be arranged in one or more shipping containers to be delivered to a solar module decommissioning site.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application claims benefit of and priority to U.S. ProvisionalPatent Application No. 63/124,844 filed Dec. 13, 2020, which is hereinincorporated by reference in its entirety.

FIELD OF INVENTION

Embodiments described herein are related to the field of recyclingend-of-life solar modules.

BACKGROUND OF THE INVENTION

Photovoltaic solar modules are an increasingly popular method ofgenerating electricity. In the US alone, installed power-generatingcapacity multiplied by a factor of nearly 20 from 2010 to 2019 and isonly expected to increase. These modules have a useful life of about 20to 30 years before they must be decommissioned and replaced. While thenumber of end-of-life cells is currently relatively low, the cellsinstalled in the past decade will generate a huge amount of waste in thecoming years.

Currently, the most prevalent technology for recycling these modulesrequires the burning of the encapsulant that binds the front layer andpolymer back sheet to the solar cells, a process called pyrolysis. Thisis a lengthy process that causes the emission of combustion gases,leaved burnt debris on the solar cells that makes them difficult torecycle, and leaves burn marks on the glass which prevents the glassfrom being reused without an additional remelting process. Furthermore,the burning process requires specialized equipment that is not easilytransportable. Solar modules therefore generally must be shipped todedicated recycling centers and processed, and then the recoveredmaterials must be shipped again to manufacturers.

Accordingly, a solar module recycling process that does not requirepyrolysis and that could be deployed directly to decommissioning siteswould be advantageous.

SUMMARY OF THE INVENTION

In some embodiments, a method of preparing a solar module for recyclingcomprises providing the solar module comprising a plurality of solarcells, a front layer coupled to the plurality of solar cells by a firstencapsulant layer; and a back sheet coupled to the plurality of solarcells by a second encapsulant layer, placing the solar module in atemperature-controlled and humidity-controlled environment, applyingelectromagnetic radiation with wavelengths less than about 100 nm to thesolar module in in environment to debond the first encapsulant layer andthe second encapsulant layer, separating the front layer from theplurality of solar cells, separating the back sheet from the pluralityof solar cells, and collecting valuable materials from the plurality ofsolar cells.

In some aspects of the method, the front layer is separated from theplurality of solar cells by a first peel block and the back sheet isseparated from the plurality of solar cells by a second peel block. Insome aspects of the method, the front layer and the back sheet areremoved simultaneously.

In some aspects of the method, the front layer and the back sheet areseparated from the plurality of solar cells by one peel block.

In some aspects of the method, the electromagnetic radiation is UVradiation with a wavelength under 100 nm, the temperature is above about50° C. and below about 374° C., and the relative humidity is above about30%. In some other aspects of the method, the electromagnetic radiationis X-ray radiation, the temperature is above about 50° C. and belowabout 374° C., and the relative humidity is above about 30%.

In some aspects of the method, each peel block comprises a tapered frontedge and is configured to emit humidified air at a temperature aboveabout 50° C. and below about 374° C., and a relative humidity of aboveabout 30%.

In some aspects of the method, the method further comprises providing asolar module assembly comprising a plurality of solar modules, a frame,one or more module power cables, and a junction box, separating theframe, the one or more module power cables, and the junction box fromthe plurality of solar modules, selecting a solar module from theplurality of solar modules, and preparing the solar module forrecycling.

In some aspects of the method, the method further comprises selecting asubsequent solar module from the plurality of solar modules, preparingthe subsequent solar module for recycling, and repeating for each of theplurality of solar modules.

In some embodiments, a method for rapidly debonding encapsulant in asolar module comprises placing the solar module in atemperature-controlled and humidity-controlled environment, and applyingelectromagnetic radiation with wavelengths less than about 100 nm to thesolar module.

In some aspects of the method, the electromagnetic radiation isultraviolet radiation with a wavelength under 100 nm, the temperature isabove about 50° C. and below about 374° C., and the relative humidity isabove about 30%. In some other aspects of the method, theelectromagnetic radiation is X-ray radiation, the temperature is aboveabout 50° C. and below about 374° C., and the relative humidity is aboveabout 30%.

In some embodiments, a system for preparing a solar module assembly forrecycling comprises a vessel configured to control temperature andhumidity and to emit electromagnetic radiation with wavelengths lessthan about 100 nm toward a solar module of the solar module assembly,the solar module comprising a plurality of solar cells, a front layercoupled to the plurality of solar cells by a first encapsulant layer,and a back sheet coupled to the plurality of solar cells by a secondencapsulant layer, and one or more peel blocks configured to separatethe front layer and the back sheet from the plurality of solar cells.

In some aspects of the system, the electromagnetic radiation isultraviolet radiation, the temperature is above about 50° C. and belowabout 374° C., and the relative humidity is above about 30%. In someother aspects of the system, the electromagnetic radiation is X-rayradiation, the temperature is above about 50° C. and below about 374°C., and the relative humidity is above about 30%.

In some aspects of the system, the system is configured to betransported in one or more shipping containers.

In some aspects of the system, the system further comprises one or moreof a frame storage bin, a junction box storage bin, a cable storage bin,a front layer storage bin, and a solar cell storage bin.

In some aspects of the system, the system further comprises a controlunit configured to provide power to the system and to control thecomponents of the system.

The foregoing summary is illustrative only and is not intended to be inany way limiting. In addition to the illustrative aspects, embodiments,and features described above, further aspects, embodiments, and featureswill become apparent by reference to the following drawings and thedetailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features of the present disclosure will becomemore fully apparent from the following description and appended claims,taken in conjunction with the accompanying drawings. Understanding thatthese drawings depict only several embodiments in accordance with thedisclosure and are, therefore, not to be considered limiting of itsscope, the disclosure will be described with additional specificity anddetail through use of the accompanying drawings.

FIGS. 1A, 1B, and 1C illustrate examples of a solar cell, a solarmodule, and a solar module assembly, respectively.

FIG. 2 illustrates one implementation of a method preparing a solarmodule for recycling.

FIG. 3 illustrates one implementation of a system for preparing a solarmodule assembly for recycling.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the following detailed description, reference is made to theaccompanying drawings, which form a part hereof. In the drawings,similar symbols typically identify similar components, unless contextdictates otherwise. The illustrative embodiments described in thedetailed description, drawings, and claims are not meant to be limiting.Other embodiments may be utilized, and other changes may be made,without departing from the spirit or scope of the subject matterpresented here. It will be readily understood that the aspects of thepresent disclosure, as generally described herein, and illustrated inthe figures, can be arranged, substituted, combined, and designed in awide variety of different configurations, all of which are explicitlycontemplated and made part of this disclosure.

Described herein are systems and methods for efficiently recyclingphotovoltaic solar module assemblies with minimal damage to the valuablecomponent materials. EMR with wavelengths less than about 100 nm can beapplied to the solar modules under controlled temperature and humidityconditions to break down the encapsulant layers. In some embodiments, amethod is provided for applying the radiation and then separating thefront layer and back sheet from the solar cells to recycle the componentparts. In some embodiments, a system is provided for performing therecycling methods in one or more portable shipping containers.

FIG. 1A depicts a solar cell 100. A solar cell 100, also known as aphotovoltaic cell, is an electrical device that converts the energy oflight directly into electricity using the photovoltaic effect. Solarcells 100 are most commonly made from a thin, square wafer ofcrystalline silicon (C-Si). Sizes vary, but an individual cell iscommonly about 6 to 8 inches square and about 5 to 500 um thick. Thinstrips of metal, most often silver, may be printed onto the wafer, withrelatively thicker strips called busbars 102 running in one directionand relatively thinner strips called fingers 104 running perpendicularto the busbars 102. The busbars 102 and fingers 104 can collect theelectricity generated by the wafers.

FIG. 1B depicts a solar module 110. A solar module 110 is an assembly ofsolar cells 100 mounted in a panel for installation in a solar moduleassembly 120. Solar cells 100 may be arranged into a thin, grid-likesolar cell sheet 114, most commonly in a rectangle shape with 6 columnsand 10 to 12 rows of cells. The cells may be encased in a front layer112, which is outward facing and light-transmissive layer, such as butnot limited to glass, and a back sheet 116. There may be a firstencapsulant layer 118 a between the front layer 112 and the solar cells100 and a second encapsulant layer 118 b between the back sheet 116 andthe solar cells 100, which adhere the layers together. In someembodiments, the encapsulant layers 118 may consist of a single adherentmaterial, in another embodiment, the encapsulant layers 118 may comprisemore than one material, such as bi-layers or multi-layers, oralternatively may comprise heterogeneous layers, such as where the firstencapsulant layer 118 a and the second encapsulant layer 188 b differ.The encapsulant material may be, but is not limited to, ethyl vinylacetate (EVA) or polyolefin elastomer (POE).

FIG. 1C depicts a solar module assembly 120. A solar module assembly 120is the final installed product used to produce electricity from thesolar cells 100. A solar module assembly 120 may include a frame 122used to support one or more solar modules 110, keeping them off theground or mounted to a roof, and optionally angled to increase lightexposure from the sun or other light source. The frame 122 may be madeof a recyclable metal such as, but not limited to, aluminum. A solarmodule assembly 120 also may include a junction box 124 and one or moremodule power cables 126 needed to transmit the electricity from thesolar modules 110 to the electrical grid or to electrical devicesconnected to the assembly.

Because of the rapidly expanding use of solar modules, recovering andrecycling the valuable materials is becoming increasingly important. Thematerials that can potentially be recovered include: the metals from theframe 122, the glass from the front layer 112, the silicon from thesolar cells 100, metals including silver and copper from the busbars 102and fingers 104, the junction boxes 124, the module power cables 126,and polymer from the back sheet 116. In order to recycle the materialsin the solar module 110, the solar cells 114, front layer 112, and backsheet 116 must be decoupled from the encapsulant layers 118. Pyrolysismay be used to burn the encapsulant away. However, this process leavesdebris and residue on the front layer 112 and the solar cells 114 thatmake it difficult to recycle the silicon from the solar cells 100 andmetals from the busbars 102 and fingers 104, and make it impossible toreuse the front layer 112 without crushing and remelting the glass.

One implementation of the present disclosure, relates to a process ofrapidly debonding the encapsulant layers 118 of the solar module 110.Under normal operating conditions, encapsulant in a solar module 110breaks down over years or decades due to exposure to UV light from thesun. The UV light causes microscopic cracks to form in the EVA polymerin a process called crazing causing the encapsulant to break down anddebond from the other layers. Exposure to higher energy EMR acceleratesthis process and breaks down the polymer faster than the polymer wouldnaturally degrade in an exposed environment, such as due to sunexposure. It is well known that, according to Planck's Theory, theenergy of EMR is inversely proportional to its wavelength. In thisimplementation, the debonding process may be greatly accelerated usingtargeted EMR with wavelengths less than about 100 nm. Furthermore,experimental data has shown that exposure to high temperature andrelative humidity dramatically increases the debonding rate and reducesthe adhesion of the encapsulant layers 118. In this implementation, theEMR is applied in a high temperature and high relative humidityenvironment 212, further accelerating the debonding process. Under theseconditions, encapsulant layers 118 can be reduced to non-adhesive flakesor dust in a matter of minutes or seconds.

In some embodiments, the solar module 110 may be placed in anenvironment 212 in which the relative humidity is at least about 30% andthe temperature is above about 50° C. and below about 374° C. while EMRis applied. The environment 212 may be contained in a closed vessel 330in which the temperature and humidity are maintained and the EMR isemitted so that users are not exposed to the EMR. The EMR may cause theencapsulant to debond from the front layer 112, solar cells 114, andback sheet 116 much faster than under natural conditions. Thetemperature of the environment 212 can be increased, for example, usinga heater and the humidity can be increased, for example, using a waterboiler to produce water vapor. A water boiler may also be used toincrease both humidity and temperature.

Another implementation, shown in FIG. 2, relates to a method ofrecycling a solar module 110 using targeted EMR to break down theencapsulant layers 118 so that the front layer 112 and back sheet 116can be separated. A solar module 110 may be provided at providing step200. The solar module 110 may be placed in a temperature-controlled andhumidity-controlled environment 212 at placing step 210. Fox example,the environment may be held at a relative humidity above about 30% and atemperature above about 50° C. and below about 374° C. In someembodiments, this environment 212 may be an enclosed chamber and mayinclude shielding, such as lead shielding, to protect users from theEMR. The solar module may be held in place by one or more vacuum chucksor may rest on surface that allows most of the front and back sides ofthe module to be exposed, such as a grate. The module may also be placedon an EMR-transmissive surface, such as glass, such that EMR passesthrough the surface and reaches the encapsulant. While inside thecontrolled environment 212, EMR 224 may be applied from both sides ofthe solar module 110 by one or more emitters 222 at applying step 220.In other embodiments, EMR 224 may be applied from one side of the solarmodule 110 at a time, turning the module over in between, In otherembodiments, EMR 224 may be applied only from one side, and may requireextra time to break down the encapsulant layer farther from the emitter222. In some embodiments, the controlled environment 212 may beconfigured to be movable, such that the environment 212 can be broughtto a stationary solar module 110 rather than placing the solar module110 in the environment 212.

In some embodiments, the emitter 222 may be in a rod shape, emitting EMR224 along a longitudinal edge. The emitter 222 may be fixed in positionwhile the solar module 110 moves underneath it, allowing all of thesolar module 110 to be exposed to the EMR 224. Alternatively, theemitter 222 may be configured to be movable, such that it passes overall of the solar module 110. In other embodiments, the emitter 222 andthe solar module 110 may both remain stationary during the applying step220.

After the EMR 224 has been applied and the encapsulant layers 118 havedebonded from the other module components, the solar modules 110 may befed into one or more peel blocks 232, shown at separating step 230. Thepeel blocks 232 may be and tapered to a sharp front edge such that thefirst peel block 232 a can be forced between the front layer 112 and thesolar cell sheet 114, and the second peel block 232 b can be forcedbetween the back sheet 116 and the solar cell sheet 114 in order toseparate the layers. In various embodiments, the separating step 230 maybe carried out inside or outside the temperature and humidity controlledenvironment 212. In some embodiments, the peel blocks 232 may emit hothumidified air with air from openings near their front edges. Thehumidified air emitted from the peel blocks 232 may be at a controlledtemperature above about 50° C. and below about 374° C. and a controlledrelative humidity above about 30%. When the separating step 230 isperformed inside the temperature and humidity controlled environment212, the humidified air emitted from the peel blocks 232 may helpcontrol the temperature and humidity inside the environment. Thehumidified air emitted may be at a sufficient pressure to blow away theremaining flakes or dust from the encapsulant layers 118 and furtherfacilitate the separation of the layers.

The peel blocks 232 may be made out of a metal, such as, but not limitedto steel. The tapered edge of the peel blocks 232 may be “sharp” enoughto fit between the front layer 112 and the solar cell sheet 114, andbetween the back sheet 116 and the solar cell sheet 114. In embodimentsthat include a high-pressure humidified air stream emitted by the peelblocks 232, the pressure may create additional separation between thesolar cell sheet 114 and the front layer 112 and back sheet 116 beforethe front edge makes contact with the module. A heater may be used toheat water from a tank or other water source to humidify the air streamemitted from the peel blocks 232. The heater and/or the water source maybe integrated into the peel blocks 232 themselves. Alternatively, theheater may heat water to create the humidified air which is delivered tothe peel blocks 232 by a fluidic channel, such as a hose or pipe.

In some embodiments, multiple peel blocks 232 may operatesimultaneously, separating the solar cell sheet 114 from the back sheet116 and the front layer 112 in one step. In other embodiments, the frontlayer 112 may be separated from the solar cell sheet 114 in one step andthe back sheet 116 separated from the solar cell sheet 114 in a separatestep. If the steps are not performed simultaneously, one peel block 232may be used to perform both steps by feeding the solar module 110through the peel block 232 once, turning the remaining layers of thesolar module 110 over, and feeding the remaining layers through a secondtime. The peel blocks 232 may be arranged so as to not contact the solarcell sheet 114 or to make only incidental contact with the solar cellsheet 114. In either case, the solar cell sheet 114 is not damaged bythe action of the peel blocks 232 and may remain intact for reuse orrecycling.

In some embodiments, the solar module 110 may be fed into the peelblocks 232 by a conveyor or roller system. Alternatively, the solarmodule 110 may be moved by one or more robotic arms. The robotic armsmay use suction to hold the solar module 110 by the front layer 112 orthe back sheet 116. As the solar module 110 passes through the peelblocks 232, one or more clamps may clamp onto one or more of the backsheet 116, solar cell sheet 114, or front layer 112 to pull theremainder of the solar module 110 through the peel blocks 232. A clampmay be used to hold the solar cell sheet 114 in place while the frontlayer 112 and back sheet 116 are removed.

In some embodiments, the method may be repeated for multiple solarmodules 110. After the front layer 112 and back sheet 116 are separatedfrom the solar cell sheet 114, the respective layers may be sorted intoseparate containers or bins (e.g. front layer storage bin 312, solarcell storage bin 314, and back sheet storage bin 316) for reuse orrecycling, shown at sorting and collecting step 240. The front layer 112may be removed without damage and may therefore be reused withoutcrushing and remelting. The back sheet 116 contains polymer materialsthat may be recovered and recycled. The solar cell sheet 114 containssilicon and valuable metals which can be manually or automaticallyseparated, recovered, and recycled or reused. The valuable materialscontained in the solar modules may be sorted and collected at sortingand collecting step 240. Because pyrolysis is not used to burn away theencapsulant, the solar cell sheet 114, front layer 112, and back sheet116 remain substantially intact and without damage from the burning ordiscoloration from the burnt encapsulant. This allows for a much higherrecovery rate with less processing time than recycling methods that relyon pyrolysis.

In some embodiments, the process of separating the materials forrecycling may be fully or partially automated. For example, the solarmodules 110 may be placed into the temperature and humidity controlledenvironment 212 where the EMR 224 is applied, and may then beautomatically carried to the peel blocks 232 by actuators, conveyors, orrobotic arms. Alternatively, the solar modules 110 may be placed onto aconveyor that carries the solar modules 110 into the temperature andhumidity-controlled environment 212 where the EMR 224 is applied, andthen the solar modules 110 may automatically be carried into the peelblocks 232 by the same or a different conveyor. The separated layers maythen be automatically sorted into separate bins for reuse or recyclingusing individual conveyors, chutes, or other mechanisms. In somealternative embodiments, the solar modules 110 may be manually movedinto place for each step and the separated layers may be manually sortedfor reuse or recycling.

In some embodiments, a method is provided for preparing full solarmodule assemblies 120, each containing a plurality of solar modules 110for reuse or recycling. One or more junction boxes 124 and one or moremodule cables 126 may be removed and set aside for reuse or recycling.The solar modules 110 can be removed from their frames 122 and theframes 122 can be set aside for reuse or recycling. A bin may beprovided for each component group for convenient sorting and transportat the conclusion of the process. The modules may then be treated withEMR 224 at controlled temperature and humidity and fed through peelblocks 232 as described above and the component materials are set asidefor reuse or recycling.

Another implementation of the present disclosure, relates to a systemfor portable recycling of solar module assemblies 120. Due to the largekilns required, recycling systems that use pyrolysis to remove theencapsulant cannot easily be moved. The current implementation insteaduses EMR under controlled temperature and humidity to debond theencapsulant from the other layers of the module. The equipment needed toproduce these conditions is smaller than kilns needed for pyrolysis andcan more easily be moved. In some embodiments of the present disclosure,the necessary equipment may be arranged in a one or more of shippingcontainers. The containers may be delivered directly to a site where thesolar module assemblies 120 are being decommissioned, or to any locationwhere it would be advantageous to deconstruct the assemblies. This willsave energy and logistical costs in the transportation and delivery ofsolar module assembly 120 components to recycling centers

FIG. 3 shows an embodiment of a system 300 for portable recycling ofsolar module assemblies 120. The system 300 may contain assemblydisassembly unit 301 and module disassembly unit 311. Each unit may becontained in one or more shipping containers. For example assemblydisassembly unit 301 may be contained in one shipping container andmodule disassembly unit 311 may be contained in a second shippingcontainer. Alternatively both the assembly disassembly unit 301 and themodule disassembly unit 311 may be contained in a single shippingcontainer. Individual components of the system 300 may remain in theshipping containers during use or may be moved outside of the containersafter delivery of the system 300 to a decommissioning site. Solar moduleassemblies 120 are disassembled at solar module assembly disassemblyunit 302. The solar module assembly frames 122 are disassembled and thesolar modules 110 are removed. Pieces of the frame 122 are stored in aframe storage bin 304 for reuse or recycling. Junction boxes 124 areremoved from the solar module assembly 120 and stored in the junctionbox storage bin 306 for reuse or recycling. Module cables 126 areremoved from the solar module assembly 120 and stored in a cable storagebin 308. The solar modules 110 may then be moved to module disassemblyunit 311.

The same or a separate shipping container may contain the equipmentnecessary to separate the layers of the solar modules 110 in the moduledisassembly unit 311. The equipment may include a vessel 330 configuredto create a temperature and humidity controlled environment 212 andwhich contains one or more EMR emitters 222, one or more peel blocks 232to separate the layers, and a conveyor, roller, robotic arm, or actuatorsystem to move the modules to the various stages. The system 300includes a front layer storage bin 312, a solar cell storage bin 314,and a back sheet storage bin 316. Moving of the components in the system300 and placement of the components into various binds may beaccomplished either by hand by an operator of the system 300 or byautomated or semi-automated means. After the components have been sortedinto their respective bins, the bins can be delivered to variousprocessing and recycling facilities for the recovery of valuablematerials.

A control unit 320 may be provided to supply power and control thecomponents of the system 300. The control unit 320 may be providedwithin one of the assembly disassembly unit 301 or the moduledisassembly unit 311 or outside of both. The control unit 320 may drawpower from the electrical grid, a generator, or by the active solarmodules remaining at the decommissioning site. The control unit 320 mayinclude an energy storage system, such as a battery, to allow operationwhen power is not available. The control unit 320 may include a memorycapable of storing commands and other data. The control unit 320 mayinclude a processor capable of executing commands, and receiving datafrom the components of the system. The control unit 320 may include auser interface to display system data, as well as one or more inputdevices the allow commands to be input by an operator.

The control unit 320 may send commands to the automated components ofthe system 300, such as actuators and conveyors. An operator may provideinputs to the control unit 320 to move the solar module assembly 120components through the system 300. Alternatively, the control unit 320may execute all the commands necessary to deconstruct the solar moduleassembly 120 without input from an operator at each step. For example,an operator could place a solar module assembly 120 into position, inputa command to the control unit 320 and the control unit 320 would executeall commands necessary to automate the deconstruction of the assembly.Alternatively, certain steps of the process could be executed withoutinput from an operator while other steps would not require an input. Thecontrol unit 320 may allow operators to control the disassembly stepswithout having close contact with moving parts or EMR emitters 222,which increases the safety of the system 300.

Various embodiments are described in the general context of methodsteps, which may be implemented in one embodiment by a program productincluding computer-executable instructions, such as program code,executed by computers in networked environments. Generally, programmodules include routines, programs, objects, components, datastructures, etc. that perform particular tasks or implement particularabstract data types. Computer-executable instructions, associated datastructures, and program modules represent examples of program code forexecuting steps of the methods disclosed herein. The particular sequenceof such executable instructions or associated data structures representsexamples of corresponding acts for implementing the functions describedin such steps.

Software and web implementations of the present invention could beaccomplished with standard programming techniques with rule based logicand other logic to accomplish the various database searching steps,correlation steps, comparison steps and decision steps. It should alsobe noted that the words “component” and “module,” as used herein and inthe claims, are intended to encompass implementations using one or morelines of software code, and/or hardware implementations, and/orequipment for receiving manual inputs.

As used herein, the singular forms “a”, “an” and “the” include pluralreferents unless the context clearly dictates otherwise. Thus, forexample, the term “a member” is intended to mean a single member or acombination of members, “a material” is intended to mean one or morematerials, or a combination thereof.

The terms “coupled,” and the like as used herein mean the joining of twomembers directly or indirectly to one another. Such joining may bestationary (e.g., permanent) or moveable (e.g., removable orreleasable). Such joining may be achieved with the two members or thetwo members and any additional intermediate members being integrallyformed as a single unitary body with one another or with the two membersor the two members and any additional intermediate members beingattached to one another.

While this specification contains many specific implementation details,these should not be construed as limitations on the scope of anyembodiments or of what may be claimed, but rather as descriptions offeatures specific to particular implementations of particularembodiments. Certain features described in this specification in thecontext of separate implementations can also be implemented incombination in a single implementation. Conversely, various featuresdescribed in the context of a single implementation can also beimplemented in multiple implementations separately or in any suitablesubcombination. Moreover, although features may be described above asacting in certain combinations and even initially claimed as such, oneor more features from a claimed combination can in some cases be excisedfrom the combination, and the claimed combination may be directed to asubcombination or variation of a subcombination.

Thus, particular implementations of the disclosure have been described.Other implementations are within the scope of the following claims. Insome cases, the actions recited in the claims can be performed in adifferent order and still achieve desirable results. In addition, theprocesses depicted in the accompanying figures do not necessarilyrequire the particular order shown, or sequential order, to achievedesirable results. In certain implementations, multitasking and parallelprocessing may be advantageous.

1. A method of preparing a solar module for recycling, the methodcomprising: providing the solar module comprising a plurality of solarcells, a front layer coupled to the plurality of solar cells by a firstencapsulant layer, and a back sheet coupled to the plurality of solarcells by a second encapsulant layer; placing the solar module in atemperature-controlled and humidity-controlled environment; applyingelectromagnetic radiation with wavelengths less than about 100 nm to thesolar module in the environment to debond the first encapsulant layerand the second encapsulant layer; separating the front layer from theplurality of solar cells; separating the back sheet from the pluralityof solar cells; and collecting recyclable materials from the pluralityof solar cells, wherein the front layer is separated from the pluralityof solar cells by a first peel block and the back sheet is separatedfrom the plurality of solar cells by a second peel block, and whereineach peel block comprises a tapered front edge and is configured to emithumidified air at a temperature above about 50° C. and below about 374°C. and a relative humidity of above about 30%.
 2. (canceled)
 3. Themethod of claim 1, wherein the front layer and the back sheet areremoved simultaneously.
 4. The method of claim 1, wherein the frontlayer and the back sheet are separated from the plurality of solar cellsby a peel block.
 5. The method of claim 1, wherein the electromagneticradiation is UV radiation with a wavelength under 100 nm, thetemperature is above about 50° C. and below about 374° C., and therelative humidity is above about 30%.
 6. The method of claim 1, whereinthe electromagnetic radiation is X-ray radiation, the temperature isabove about 50° C. and below about 374° C., and the relative humidity isabove about 30%.
 7. (canceled)
 8. (canceled)
 9. A method of preparing asolar module assembly for recycling, the method comprising: providingthe solar module assembly comprising a plurality of solar modules, aframe, one or more module power cables, and a junction box; separatingthe frame, the one or more module power cables, and the junction boxfrom the plurality of solar modules; selecting a solar module from theplurality of solar modules; and preparing the solar module for recyclingaccording to claim
 1. 10. The method of claim 9 further comprising:selecting a subsequent solar module from the plurality of solar modules;preparing the subsequent solar module for recycling according to claim1; and repeating for each of the plurality of solar modules.
 11. Amethod for rapidly debonding encapsulant in a solar module comprising:placing the solar module in a temperature-controlled andhumidity-controlled environment; and applying X-ray radiation withwavelengths less than 10 nm to the solar module.
 12. (canceled)
 13. Themethod of claim 11, wherein the temperature is above about 50° C. andbelow about 374° C. and the relative humidity is above about 30%. 14-20.(canceled)